INSTRUCTION TO SERVICE
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SECTION:

400

WRITTEN BY:

Jeff Kosheluk

SUBJECT:

Rework corrosion issues on the underbody and A/C compartment. This will
include removing debris buildup on outer lower tubes, rust staining, lower
impact panel bracket corrosion (depending on property) and applying Krown T40 inside the tubes on the underbody chassis. This would include the use of
Salt Eliminator.

Structures

ITS5785
THIS DOCUMENT AND THE CONTENTS DISCUSSED HEREIN ARE THE CONFIDENTIAL AND
PROPRIETARY INFORMATION OF NEW FLYER INDUSTRIES CANADA ULC AND NEW FLYER OF
AMERICA INC. AND ARE DISCLOSED BY NEW FLYER IN CONFIDENCE. THIS DOCUMENT AND THE
CONTENTS HEREIN ARE NOT TO BE DISCLOSED BY THE INTENDED RECIPIENT WITHOUT THE PRIOR
WRITTEN AUTHORIZATION OF NEW FLYER. ANY UNAUTHOIZED DISCLOSURE, REPRODUCTION OR
OTHER DISTRIBUTION OF THIS DOCUMENT OR INFORMATION IS STRICTLY PROHIBITED AND MAY
RESULT IN ACTION BEING TAKEN AGAINST THE PARTY MAKING THE UNAUTHORIZED DISCLOSURE.
THIS DOCUMENT AND ALL COPIES HEREOF MUST BE RETURNED TO NEW FLYER UPON REQUEST.

PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. Raise coach in accordance with the New Flyer Service Manual.
3. Once bus is raised, install stands below jacking pads at the 4 places on the underbody.

PART A: REMOVAL OF IMPACT PANELS (IF BUS IS EQUIPPED WITH IMPACT PANELS)
4. For buses that have impact panels, the impact panels will need to be removed and set aside. Remove hardware.
Old mounting hardware will be discarded and new hardware applied. Remove on both sides of the buses.

FIGURE 1: SHOWN IMPACT PANELS BEING REMOVED.

5. Once impact panels removed, inspect to see if debris is inside the channels of the impact brackets. See Figure
2 below showing a typical image with debris inside the channel.

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Shown typical debris inside lower
Impact panel support bracket that
Needs to be removed.

FIGURE 2: TYPICAL VIEW OF DEBRIS INSIDE OF LOWER IMPACT MOUNTING CHANNEL.
6. Remove all loose scaling and debris on the outside of the lower mounting impact panel brackets – Figure 2A.
Use an Air Needle De-Scaler on the outside surface to remove all loose scaling. Refer to Figure 2B showing
tool. Note: Only brackets with heavy surface scaling will use the de-scaler tool.

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FIGURE 2A: DEBRIS BUILDUP ON LOWER IMPACT PANEL BRACKET.

FIGURE 2B: AIR NEEDLE DE-SCALER USED ON OUTSIDE SURFACE OF LOWER IMPACT MOUNTING BRACKETS

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7. Repeat step 6 on the outside of all lower impact mounting brackets. Only if heavy scaling exists as shown as
per Figure 2a.
8. Turn the front tire to allow for access to gain access to allow for drilling the 1/2” hole. Tire will be rotated when
working on the opposite hole at the wheel arch area. Refer to Figure 3.

FIGURE 3: SHOWN TIRE ROTATED FOR ACCESS
9. Using a ½” drill bit, using lubricant while drilling, use the pilot hole as a reference and drill through the structure
tube at both sides of the fender wells. As well drill ½” diameter holes at the bottom of the outer tube at the
locations shown on both the curbside and street side (6 per side). Use low speed drill with a ½” unibit. Pilot hole
may be needed to be drilled. Do not remove any fender hardware. Fenders stay on and the hole can be drilled
with the fenders on. Reference Figure 4.

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FIGURE 4: SHOWN ½” HOLE DRILLED AT THE BOTTOM OF THE TUBE DIRECTLY AT THE VERTICAL
TUBE GOING UP.

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FIGURE 4A: SHOWN TYPICAL HOLE LOCATIONS ON THE STREET SIDE & CURBSIDE

FIGURE 4B: SHOWN THE PRE-DRILLED HOLE ON THE FACE OF THE TUBE THAT WILL BE
DRILLED.

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10. Blow off and remove all debris and road salt from the underbody. This also includes the area inside the engine
compartment (underside only). Refer to Figure 5 showing some examples of debris to be removed. Pressure
wash underbody chassis as well to remove heavy debris and dirt.

FIGURE 5: SHOWING TYPICAL EXAMPLES OF ROAD DEBRIS/SALT THAT NEEDS TO BE REMOVED.

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11. On the underbody of the bus, inspect and ensure that all drain holes are cleaned out and allow for drainage.
Note: For application of the Krown Salt Eliminator, refer to Appendix A for application and MSDS sheets.
12. Clean the entire underside with Krown Salt Eliminator chloride cleaner. Can be sprayed with a foam cannon or
sprayer that is attached to a pressure washer. The salt eliminator is to be foamed on and left for 10 minutes. It
can then be rinsed off. See Figure 6.

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FIGURE 6: SALT ELIMINATOR APPLIED TO THE UNDERSIDE OF THE BUS.

13. Additional cleaning with a degreaser may be required in some areas depending upon the condition of the
chassis. If a degreaser is used, it must be washed off and re-spray with salt eliminator. Refer to Figure 7.

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FIGURE 7: WHEN HEAVY DEBRIS, GREASE OR OIL STAINING EXISTS, USE OF A DEGREASER MUST BE USED.

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Clean side panels/lower impact panel brackets with Salt Eliminator

14. Foam the Salt Eliminator on to the panels and brackets/rails. Let sit for 10 minutes. Flush with water to remove
chlorides, dirt and grease that has accumulated. Refer to Figure 8.

FIGURE 8: SHOWN THE APPLICATION OF THE SALT ELIMINATOR SPRAYED ON THE PANELS AND
LOWER IMPACT PANEL BRACKETS/RAILS.

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Flush tubes with Krown Salt Eliminator
15. Typically this is what you would see inside the tubes before they are cleaned out. This is seen when using a
boroscope. Refer to Figure 9.

FIGURE 9: SHOWN THE DEBRIS/CORROSION INSIDE THE TUBES BEFORE TUBES ARE CLEANED
AND FLUSHED OUT.

16. Flush the inside the tubes thoroughly with Krown Salt Eliminator (using a foam gun). This will be done to remove
debris from the outer lower tube on both sides of the bus. This application maybe required to be completed a
couple times till all debris is removed. All the inside tubes will only need this application done once. Refer to
Figure 10.
Note: This will also include the engine header tube in the engine compartment. This must be flushed out as
well.
Refer to Figure 11.

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FIGURE 10: APPLICATION OF SALT ELIMINATOR BEING APPLIED INSIDE TUBES TO FLUSH OUT DEBRIS AND CALCIUM
BUILDUP

Shown view of engine header tube

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FIGURE 11: SHOWN (X4) DRAIN HOLES. TYPICAL ON BOTH SIDES. TUBE WILL
BE FLUSHED OUT AND THEN APPLIED WITH T-40 KROWN.

17. As the material is flushed out you will see dirt, debris, rust scale etc. coming out of the tubes with the water.
You will insert the plastic tubing into each hole and flush the material backwards and forwards multiple times to
ensure proper cleaning. Refer to figure 12.

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FIGURE 12: SHOWN DIRT AND DEBRIS COMING OUT WITH WATER WHEN FLUSHING OUT TUBES

18. You should expect to see clear water coming out from all of the holes once the application is of the salt eliminator
is applied correctly and feel confident that the tubes are free from the dirt and other debris that was plugging
them up. Refer to figure 13.

FIGURE 13: WHEN WATER COMES OUT CLEAR, THIS IS A GOOD INDICATION THAT DEBRIS AND
CALCIUM HAS BEEN REMOVED FROM THE INSIDE OF THE TUBES.

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FIGURE 13A: VIEW OF CLEAR WATER COMING OUT OF THE TUBE.

19. Shown picture views of what the tube surface will appear like once salt eliminator has been applied onto the
surface and rinsed off. Refer to Figure 14.

FIGURE 14: SHOWN SURFACE AFTER SALT ELIMINATOR APPLIED AND FLUSHED WITH WATER.

Rinse side rails/brackets and underside of bus

20. Wash the entire underside of the bus and inside of tubes as specified. Refer to figure 15.

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FIGURE 15: PRESSURE WASH UNDERSIDE OF BUS TO REMOVE SALT ELIMINATOR

Apply Krown Enviro Solve
Note: For application of the Krown Enviro Solve, refer to Appendix C for application and MSDS sheets.

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21. For areas showing rust stains (around drain holes, bracket edges, etc), use a spray bottle to apply the Enviro
Solve to the rust stain. Let sit for 60 seconds and scrub with a firm brush. The rust stain should come right off.
If the rust is deep into the metal you may need to repeat this step a second time. Refer to Figure 16.

FIGURE 16: SHOWN APPLICATION OF THE KROWN ENVIRO SOLVE APPLIED, ABSORB FOR A 1 MINUTE AND
THEN SCRUBBED OFF AS SHOWN. RINSE WITH WATER AND LET DRY.

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Note: For application of the PPG Zinc Primer and Corashield, refer to Appendix D & E for application
and MSDS sheets.
Apply zinc primer and corashield at affected areas (when dry)
22. Inspect the plastic plugs on the underbody chassis. Check to see if cracked, shrunk or missing. If so, the plugs
need to be replaced. Seal around plug before installing and then final seal once installed. If new plugs are
required, 1.5” plug (PN: 116507) or 1” plug (PN: 116511).
If you see plugs that are full of debris, they must be blown and cleaned out. Ensure there is no cracks in the
plug. See below for example.

Plug to be cleaned out & inspected for cracks
Shown example of cracked or broken plug

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23. For areas that have bare metal or have been cleaned off with Enviro solve, zinc primer should be re-applied.
Brush on and let dry. After zinc primer applied and dry, apply corashield over top. Apply 2 light coats. Other
areas that corashield has come off due to road wear must be touched up as well. Refer to Figure 17.

FIGURE 17: SHOWING PPG ZINC PRIMER APPLIED

FIGURE 17A: SHOWING CORASHIELD APPLIED (WHITE AREAS)

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Note: For application of the Krown T-40 Corrosion Inhibitor, refer to Appendix B for application and
MSDS sheets.
Krown T-40 Corrosion Inhibitor application
24. Using a Krown spray system (see the appendix for equipment) the corrosion inhibitor is to be sprayed into all
of the tubing on the chassis of the bus. The product will be “fogged” into the tubular sections. The tubes do not
need to be dry to apply the corrosion inhibitor as it will displace the moisture. Refer to Figure 18.

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FIGURE 18: SHOWN APPLICATION OF THE T-40 INTO THE TUBES

25. Once the product is applied, the product will not dry up or cure. It is designed to remain viscous so as to repel
moisture. The foam will dissipate and it will penetrate any rust scale to create a thin barrier on the metal to
protect it. Refer to figure 19.

FIGURE 19: ONCE COMPLETED THIS IS WHAT THE TUBES WILL LOOK LIKE INSIDE

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On fittings and electrical connections
26. Spray Krown T-40 on all fittings and electrical connections. Refer to Figure 20.

FIGURE 20: SHOWN ELECTRICAL CONNECTIONS AND FITTINGS SPRAYED WITH KROWN T-40

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27. Spray side rails/brackets at the lower impact panels. Refer to Figure 21.

FIGURE 21: SHOWN T-40 SPRAYED AT THE LOWER IMPACT PANEL RAILS/BRACKETS

28. Spray the entire chassis/underside of the bus and the engine door header tube. Refer to Figure 22.

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FIGURE 22: SPRAY T-40 ON THE UNDERSIDE OF THE BUS.
Note: Once the T-40 is applied on the chassis it will look “wet”. It will not cover up or hide anything that is
there. It will displace the moisture, protect the fittings and electrical connections as well as
supplement/support the corashield. Refer to Figure 23.

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FIGURE 23: SHOWN VIEW OF THE UNDERSIDE SPRAYED WITH T-40. “WET” LOOK IS THE FINAL PRODUCT
SHOWN ON THE UNDERSIDE.

29. Using the blue plastic plug (PN: 116508) with a dab of lithium grease, install at holes that were enlarged at the
fender wells (x2 per) and the ½” holes that were drilled toward the end of the tubes. Refer to Figure 24.
Note: “DO NOT PLUG” the (x4) holes on the engine header tube. They must remain open.

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FIGURE 24: SHOWN THE ½” HOLES PLUGGED WITH LITHIUM GREASE & BLUE PLUG

Note: Only complete steps 29 & 30 if the buses have impact panels. Otherwise skip to step 31.
30. Install closeouts (PN: 597554) at the end of each impact panel bracket. Typical 18 places. Ensure the area is
dry and clean for proper adhesion.
31. For buses that had impact panels removed, install new hardware (PN: 34S00024 & 30W00000) with never
seize. Tighten all hardware.
32. Turn the main battery disconnect switch to the “ON” position.

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APPENDIX A
KROWN SALT ELIMINATOR – APPLICATION SHEET

KROWN Salt Eliminator
The Krown Salt Eliminator chloride wash is a cleaner designed to help fight corrosion that is caused by
magnesium, calcium, and sodium chloride salts. Its unique formula allows the product to break the bond
formed between the chloride and the metal. Salt Eliminator creates a water repelling surface that not
only leaves a beading shine to the vehicle but also helps slow salt from reforming on the surface. Salt
Eliminator doesn’t contain any phosphates or petroleum solvents and is safe to use to remove salt stains
from carpets, upholstery, plastic, leather and vinyl. Krown Salt Eliminator is an environmentally
friendly product.
The product can be applied using the following methods:
 Foam Cannon/Gun
 Pressure Washer
 Trigger or Pump Sprayers
 Automatic Bus Wash Systems
 Underbody Wash Systems
For specifics of the application and dilution rates, as it relates to the equipment used to apply the
product, please contact Krown’s Technical department for assistance.
Areas of Application
 Interior desalting of bus floors
 Exterior washing of equipment
 Underbody de-salting
 Interior tube cleaning
 Chloride removal form radiators and electrical components
Directions for Use
Salt Eliminator is to be foamed on to the surface using any of the above mentioned methods. The Salt
Eliminator will dwell on the surface for at least 1 minute (more time will be needed depending upon the
application requirement.) The product will then be rinsed off with water.

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The product can be used with either hot or cold water. No special personal safety equipment is required
for use.
Further product information and a current MSDS is available on Krown’s web site at www.krown.com
KROWN CORPORATE
35 Magnum Drive, Schomberg, Ontario (Canada) L0G 1T0
(905) 939-8750 tel (905) 939-8710 fax
www.krown.com

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APPENDIX A
KROWN SALT ELIMINATOR – MSDS SHEET

MATERIAL SAFETY DATA SHEET
KROWN SALT ELIMINATOR

Krown

USE: Salt Remover
PHONE: 1 800-267-5744
CHEMICAL FAMILY: Blended Product

35 Magnum Drive
Schomberg, ON L0G 1T0

HAZARDOUS INGREDIENT
Ethylene glycol monobutyl

1-5

%W/W PIN/CAS#
LD50/LC50
111-76-2
LD50 1746 mg/kg

ROUTE/SPECIES
oral, rat ether

EFFECTS OF ACUTE EXPOSURE TO MATERIAL: EYES: Concentrate can cause irritation to
eye tissue SKIN: Can cause skin irritation. May cause drying of skin. INGESTION: Harmful
if ingested
EFFECTS OF CHRONIC EXPOSURE TO MATERIAL: May cause drying of skin
PRIMARY ROUTE OF ENTRY: [ ]-Inhalation [ X ]-Ingestion [ ]-Absorption
OTHER TOXIC EFFECTS: None known

EYES: Flush eyes with plenty of water for at least 15 minutes. Hold eyelids open while rinsing.
Contact a physician immediately
SKIN: Flush affected area thoroughly with water. Seek medical attention if irritation persists
INGESTION: Rinse mouth with water. Drink large volumes of water. Do not induce vomiting.
Never give anything by mouth to an unconscious patient. Contact a physician immediately
INHALATION: Remove patient to fresh air.

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FLAMMABLE: NO
FLASH POINT, CELSIUS: Not Applicable
AUTO IGNITION TEMPERATURE, CELSIUS: Not Applicable
EXTINGUISHING MEDIA: Water Fog, Dry Chemical, CO2 , Foam
SPECIAL FIRE FIGHTING PROCEDURES: appropriate to surrounding fire
HAZARDOUS COMBUSTION PRODUCTS: Oxides of carbon, hazardous fumes
EXPLOSIVE SENSITIVITY TO: Not Applicable

SPILL PROCEDURE: SMALL: Hose down with water
LARGE: Soak up with absorbent material and hold for disposal

SPECIAL HANDLING PROCEDURES AND EQUIPMENT: Wear gloves if handling
concentrated product. Avoid contact with skin and eyes. Do not take internally.
STORAGE REQUIREMENT: Avoid freezing. Store in a cool dry area in a closed container.

PERSONAL PROTECTIVE EQUIPMENT:
GLOVES: Impermeable Gloves
EYE PROTECTION: Safety Goggles
FOOTWEAR: Water Resistant
OTHER: Not required
RESPIRATORY PROTECTION: Not required for normal use
VENTILATION REQUIREMENTS: Local Ventilation

APPEARANCE:
PH: (Concentrate):
VAPOUR DENSITY
(air=1):
FREEZING POINT:

orange/red product;
fruity/citrus odour
4.1
not established
0oC

S.G. / DENSITY (g/cc):

1.017

VAPOUR PRESSURE
(mmHg):
BOILING POINT:

not established

EVAPORATION RATE
(water=1):

>1

100oC

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SOLUBILITY IN WATER:

Excellent

INCOMPATIBILITY (Material to Avoid): Sodium Hypochlorite; Peroxide
STABILITY: Stable INCOMPATIBILITY: Strong acids and oxidizing materials
HAZARDOUS DECOMPOSITION PRODUCTS: Oxides of carbon, hazardous fumes
HAZARDOUS POLYMERIZATION: Not applicable REACTIVITY: Not dangerously reactive

LD50 (Calculated): 3860 mg/kg (Oral/Rat)

LC50 (Calculated): Not established

SPILL PROCEDURE: Pick up with mop or wet-vac.
WASTE DISPOSAL: Dispose according to municipal, provincial, and federal regulations

WASTE DISPOSAL: Dispose according to municipal, provincial, and federal regulations

TDG: Not Regulated

WHMIS CLASS: Not a WHMIS controlled product
CPR Compliance: This product has been classified in accordance with hazard criteria of the CPR
and this MSDS contains all the information required by the CPR

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PREPARED BY: J. Brideau (800)267-5744
PREPARATION DATE: February 17, 2012
AMMENDED: February 13, 2015
Notice:
To the best of our knowledge, the information contained in this document is accurate. However,
neither the above named supplier nor any of its subsidiaries assumes any liability whatsoever for the
accuracy or completeness of the information contained herein. Some of the information presented in
this document is from sources other than direct test data on the substance itself. As the methods of
storage and handling, use, and disposal of the product are beyond our control, we do not assume
responsibility and expressly disclaim liability for loss, damage, or expense arising out of or in any way
connected with storage and handling, use, or disposal of this product.
Final determination of suitability of this material is the sole responsibility of the user. Materials may
present unknown hazards and should be used with caution. Although certain hazards are described
herein, we cannot guarantee that these are the only hazards that exist.

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APPENDIX B
KROWN T-40 CORROSION INHIBITOR – APPLICATION SHEET

KROWN T- 40 CORROSION INHIBITOR
The Krown T-40 is an Industrial strength Corrosion Inhibitor/Lubricant designed to protect metal
surfaces and tubing. It is safe for use on electrical components and is an environmentally friendly
product. The product is non-toxic and contains no solvents.
The product can be applied using the following methods:





Aerosol can
Pot Spray System
Pressure Pot System
Pumping System

For specifics of the application, as it relates to the equipment used to apply the product, please contact
Krown’s Technical department for assistance.
Krown T-40 is best applied when the product is heated. It is optimal to have the product at a
temperature of 140 degrees F.
Make sure the surface is clean prior to application of Krown T-40. It is preferable to clean the surface
with Krown Salt Eliminator (Chloride cleaner) prior to application. The surface does not need to be dry
prior to the T-40 application as the product will displace moisture. The product when applied will
remain wet and is not intended to “set up”. It will create a thin barrier to repel moisture.